Cushion to frame assembly mechanism

ABSTRACT

A mask assembly for treating sleep disorder including: a first frame including a first wall that at least partially delimits a breathing chamber, a second wall surrounding an opening through the first wall and defining a first substantially cylindrical surface surrounding the opening, the second wall extending from the first wall, the opening allowing the flow of pressurized gas to the breathing chamber; a second frame including a third wall defining a second substantially cylindrical surface, a fourth wall, a member extending toward a forehead support and two headgear attachment locations, the third wall extending from the fourth wall, the second cylindrical surface at least partially overlapping with the first cylindrical surface, and the second frame being configured to removably interlock with the first frame proximate the opening; and a cushion molded to the first frame and adapted to seal around at least a patient&#39;s nose.

CROSS-REFERENCE TO APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.14/484,358, filed Sep. 12, 2014, which is a continuation of U.S. patentapplication Ser. No. 13/834,189, filed Mar. 15, 2013, which is acontinuation of U.S. patent application Ser. No. 11/989,137, filed Dec.29, 2009, now U.S. Pat. No. 8,397,728, which is the U.S. national phaseof International Application No. PCT/AU2006/000035, filed Jan. 12, 2006,which claims the benefit of U.S. Provisional Application Nos.60/726,265, filed Oct. 14, 2005, and 60/734,746, filed Nov. 9, 2005,each of which is incorporated herein by reference in its entirety.

FIELD OF THE INVENTION

The present invention relates to a method and apparatus for assembling apatient interface for use in treatment of sleep disordered breathing(SDB) such as obstructive sleep apnea (OSA). In particular, the presentinvention relates to a method and apparatus for securing aface-contacting portion of a patient interface, such as a cushion, to aframe or shell of the patient interface.

BACKGROUND OF THE INVENTION

Patient interfaces, such as a mask assembly, for use with blowers andflow generators in the treatment of sleep disordered breathing (SDB)typically include a soft-patient contacting portion, such as a cushion,and a rigid shell or frame. In use, the patient interface is held in asealing position by headgear so as to enable a supply of air at positivepressure to be delivered to the patient's airways. When the cushion andframe are manufactured from different materials, they need to be heldtogether in some way. It is also generally desirable that the patientinterface be cleanable, for example, allowing a person to wash a maskbetween uses. While some semi-permanent assembly methods are available,they generally leave small gaps and crevices that can accumulate dirtand be difficult to clean. Hence, it is generally desirable that theframe and cushion include a mechanism that enables both assembly anddisassembly. It is also desirable that there be a seal between the frameand cushion to reduce or eliminate leaks from the assembly in use. Sincemany patients lack dexterity, a good design is simple and easy to usefor patients.

A number of cushion to frame assembly mechanisms are known. For example,see U.S. Pat. No. 6,412,487 to Gunaratnam, et al. and U.S. Pat. No.6,823,869 to Raje et al. Also see ResMed's MIRAGE®, ULTRA MIRAGE®,ACTIVA®, and VISTA® masks.

A problem with existing assembly mechanisms includes difficulty withalignment and assembly, e.g., both putting the cushion onto the frameand putting the cushion clip into the sub-assembly. Another problem withexisting assembly mechanisms includes difficulty with adhesive, e.g.,gluing, that does not allow disassembly for cleaning. Yet anotherproblem with existing assembly mechanisms includes overmolded parts thatcan still have points of ingress that cannot be easily cleaned, e.g.,see Respironics' ComfortCurve mask. Still another problem with existingassembly mechanisms includes interference methods that can be difficultto use on large frames, e.g. full-face mask, and can have misalignmentissues.

Thus, there is a need for an improved assembly mechanism that does notsuffer from at least one of the above-mentioned drawbacks.

SUMMARY OF THE INVENTION

One aspect of the invention relates to a cushion to frame assemblymechanism structured to facilitate assembly and provide a compliant sealbetween the cushion and the frame.

Another aspect of the invention relates to a cushion to frame assemblymechanism that includes an angled lip or flap provided to the cushioninterior wall that forms a seal against the frame.

Another aspect of the invention relates to a cushion to frame assemblymechanism that is integrated with the frame mating geometry.

Another aspect of the invention relates to a cushion to frame assemblymechanism that includes an overall wedge, taper, or angle in the slot ofthe frame that receives the cushion.

Another aspect of the invention relates to a cushion to frame assemblymechanism that includes a cushion clip.

Another aspect of the invention relates to a full-face mask assemblyincluding a frame and a cushion provided to the frame. The cushion isadapted to form a seal around the patient's nose and mouth. A flexiblelip is provided to an interior wall of the cushion. The flexible lip isadapted to engage the frame to provide a seal in use.

Another aspect of the invention relates to a full-face mask assemblyincluding a frame and a cushion provided to the frame. The cushion isadapted to form a seal around the patient's nose and mouth. The frameincludes a retaining recess that is adapted to receive a retainingportion provided to the cushion. The retaining recess has an angledconfiguration with respect to the frame.

Another aspect of the invention relates to a full-face mask assemblyincluding a frame, a cushion provided to the frame, and a clip tomaintain the cushion to the frame. The cushion is adapted to form a sealaround the patient's nose and mouth.

Another aspect of the invention relates to a full-face mask assemblyincluding a frame, a cushion provided to the frame, and a skeleton frameto maintain the cushion to the frame. The cushion is adapted to form aseal around the patient's nose and mouth. The skeleton frame includes atleast one of an upper support member adapted to support a foreheadsupport, lower headgear clip receptacles adapted to be engaged withclips provided to straps of a headgear assembly, and an annular elbowconnection seal adapted to engage an inlet conduit.

Yet another aspect of the invention relates to a full-face mask assemblyincluding a frame and a cushion provided to the frame. The cushion isadapted to form a seal around the patient's nose and mouth. The cushionincludes hooks or tabs integrally formed therewith that are adapted tointerlock with locking features integrally formed with the frame.

Yet another aspect of the invention relates to a full-face mask assemblyincluding a frame and a cushion provided to the frame. The cushion isadapted to form a seal around the patient's nose and mouth. The frameincludes outer and inner walls that define a retaining recess adapted toreceive therein a retaining portion provided to the cushion. Theretaining portion includes a flexible lip to engage the inner wall andprovide a seal in use. The retaining portion includes a space behind theflexible lip to provide the flexible lip with a range of movement.

Other aspects, features, and advantages of this invention will becomeapparent from the following detailed description when taken inconjunction with the accompanying drawings, which are a part ofdisclosure and which illustrate, by way of example, principles of thisinvention.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings facilitate an understanding of the variousembodiments of this invention. In such drawings:

FIG. 1 is a top perspective view of a mask assembly including a, cushionto frame assembly mechanism according to an embodiment of the presentinvention, the mask assembly in a pre-assembled condition;

FIG. 2 is a top perspective view of the mask assembly shown in FIG. 1,the mask assembly in an assembled condition;

FIG. 2B is a cross-sectional view through line 2B-2B in FIG. 2;

FIG. 3 is a top perspective view of a mask assembly including a cushionto frame assembly mechanism according to another embodiment of thepresent invention, the mask assembly in a pre-assembled condition;

FIG. 4 is a top perspective view of the mask assembly shown in FIG. 3,the mask assembly in an assembled condition;

FIG. 5 is a top perspective view of a mask assembly including a cushionto frame assembly mechanism according to another embodiment of thepresent invention, the mask assembly in a pre-assembled condition;

FIG. 6 is a top perspective view of a mask assembly including a cushionto frame assembly mechanism according to another embodiment of thepresent invention, the mask assembly in a pre-assembled condition;

FIG. 7 is a top perspective view of the mask assembly shown in FIG. 6,the mask assembly in a partial assembled condition;

FIG. 8 is a top perspective view of the mask assembly shown in FIG. 6,the mask assembly in an assembled condition;

FIG. 9 is a side perspective view of a mask assembly including a cushionto frame assembly mechanism according to another embodiment of thepresent invention, the mask assembly in an assembled condition;

FIG. 10 is a top perspective view of a mask assembly including a cushionto frame assembly mechanism according to another embodiment of thepresent invention, the mask assembly in a pre-assembled condition;

FIG. 11 is a top perspective view of the mask assembly shown in FIG. 10,the mask assembly in an assembled condition;

FIG. 12 is a side perspective view of a mask assembly including acushion to frame assembly mechanism according to another embodiment ofthe present invention, the mask assembly in a pre-assembled condition;

FIG. 13 is a side perspective view of the mask assembly shown in FIG.12, the mask assembly in an assembled condition;

FIG. 14 is a top perspective view of a mask assembly including a cushionto frame assembly mechanism according to another embodiment of thepresent invention, the mask assembly in a pre-assembled condition;

FIG. 15 is a top perspective view of the mask assembly shown in FIG. 14,the mask assembly in a first partial assembled condition;

FIG. 16 is a top perspective view of the mask assembly shown in FIG. 14,the mask assembly in a second partial assembled condition;

FIG. 17 is a top perspective view of the mask assembly shown in FIG. 14,the mask assembly in an assembled condition;

FIG. 18 is a top perspective view of a mask assembly including a cushionto frame assembly mechanism according to another embodiment of thepresent invention, the mask assembly in a pre-assembled condition;

FIG. 19 is a top perspective view of the mask assembly shown in FIG. 18,the mask assembly in a partial assembled condition;

FIG. 20 is a top perspective view of the mask assembly shown in FIG. 18,the mask assembly in an assembled condition;

FIG. 21 is a top perspective view of a cushion according to anotherembodiment of the present invention;

FIG. 22 is a top perspective view of a cushion including a cushion toframe assembly mechanism according to another embodiment of the presentinvention;

FIG. 23 is a cross-sectional view of the cushion shown in FIG. 22;

FIG. 24 is a cross-sectional view of the cushion shown in FIG. 22engaged with a mask frame according to an embodiment of the presentinvention;

FIGS. 25-26 are cross-sectional views illustrating a cushion clip tomaintain the engagement between the frame and the cushion shown in FIG.24;

FIG. 27 is a perspective view of a mask frame according to anotherembodiment of the present invention;

FIG. 28 is a cross-sectional view of the frame shown in FIG. 27 engagedwith a mask cushion according to an embodiment of the present invention;

FIGS. 29-32 are cross-sectional views illustrating a cushion to frameassembly mechanism according to another embodiment of the presentinvention;

FIGS. 33-34 are cross-sectional views illustrating a bottom assemblingframe clip to maintain the engagement between the frame and the cushionshown in FIGS. 29-32;

FIGS. 35-39 illustrate a top assembling frame clip to maintain theengagement between the frame and the cushion shown in FIGS. 29-32;

FIG. 40 illustrates a mask frame according to another embodiment of thepresent invention, the mask frame adapted for use with the cushion shownin FIGS. 29-32;

FIGS. 41-44 illustrate a cushion to frame assembly mechanism accordingto yet another embodiment of the present invention;

FIGS. 45-46 illustrate a cushion to frame assembly mechanism accordingto another embodiment of the present invention;

FIGS. 47-49 illustrate a cushion to frame assembly mechanism accordingto another embodiment of the present invention;

FIGS. 50-51 illustrate alternative frame clip designs;

FIG. 52 is a top perspective view of a mask assembly including a cushionto frame assembly mechanism according to another embodiment of thepresent invention, the mask assembly in a pre-assembled condition;

FIG. 53 is a top perspective view of the mask assembly shown in FIG. 52,the mask assembly in a partial assembled condition;

FIG. 54 is a top perspective view of the mask assembly shown in FIG. 52,the mask assembly in an assembled condition;

FIG. 55 is a cross-sectional view of the mask assembly shown in FIG. 52;

FIG. 56 is a top view of the mask assembly shown in FIG. 52;

FIGS. 57-61 are various views of the frame of the mask assembly shown inFIG. 52 and showing exemplary dimensions of an embodiment;

FIGS. 62-66 are various views of the cushion of the mask assembly shownin FIG. 52 and showing exemplary dimensions of an embodiment;

FIGS. 67-71 are various views of the cushion clip of the mask assemblyshown in FIG. 52 and showing exemplary dimensions of an embodiment;

FIG. 72 is a top perspective view of a mask assembly including a cushionto frame assembly mechanism according to another embodiment of thepresent invention, the mask assembly in a pre-assembled condition;

FIG. 73 is a top perspective view of the mask assembly shown in FIG. 72,the mask assembly in a partial assembled condition;

FIG. 74 is a top perspective view of the mask assembly shown in FIG. 72,the mask assembly, in an assembled condition;

FIG. 75 is a cross-sectional view of the mask assembly shown in FIG. 72;

FIG. 76 is a top view of the mask assembly shown in FIG. 72;

FIGS. 77-81 are various views of the frame of the mask assembly shown inFIG. 72 and showing exemplary dimensions of an embodiment;

FIGS. 82-86 are various views of the cushion of the mask assembly shownin FIG. 72 and showing exemplary dimensions of an embodiment;

FIGS. 87-91 are various views of the frame clip of the mask assemblyshown in FIG. 72 and showing exemplary dimensions of an embodiment;

FIG. 92 is an exploded top perspective view of a mask assembly includinga cushion to frame assembly mechanism according to another embodiment ofthe present invention, the mask assembly being in a pre-assembledcondition;

FIG. 93 is a top perspective view of the mask assembly shown in FIG. 92,the mask assembly being in a partial assembled condition;

FIG. 94 is a top perspective view of the mask assembly shown in FIG. 92,the mask assembly being in an assembled condition;

FIG. 95 are cross-sectional views of the assembled mask assembly shownin FIG. 94;

FIG. 96 is a cross-sectional view of the cushion of the mask assemblyshown in FIG. 92;

FIGS. 97-105 are various views of the cushion clip of the mask assemblyshown in FIG. 92 and showing exemplary dimensions of an embodiment; and

FIGS. 106-107 are cross-sectional views at top and bottom portions of amask assembly according to another embodiment of the present invention.

DETAILED DESCRIPTION OF ILLUSTRATED EMBODIMENTS

The following includes descriptions of mask assemblies including cushionto frame assembly mechanisms according to several illustratedembodiments of the present invention. In each of the illustratedembodiments, the mask assembly includes a cushion that is adapted to beremovably connected to a frame via a cushion to frame assemblymechanism.

The cushion to frame assembly mechanism provides an interface betweenthe cushion and frame to facilitate assembly and disassembly. Inaddition, the cushion to frame assembly mechanism may be structured toprovide a compliant seal between the cushion and frame and reduce oreliminate the risk of leakage.

In the illustrated embodiment, the cushion and frame form a part of afull-face mask. Specifically, the cushion provides a seal around thepatient's nose and mouth to enable the delivery of breathable gas to thepatient's nose and mouth. However, aspects of the present invention maybe applicable to other breathing arrangements, e.g., a nasal mask, amouth mask, etc. Also, each illustrated embodiment includes featuresthat may be used with and/or in the other illustrated embodiments, aswould be apparent to those of ordinary skill in the art.

1. First Embodiment of Cushion to Frame Assembly Mechanism

FIGS. 1 2, and 2B illustrate a mask assembly 10 including a cushion toframe assembly mechanism according to an embodiment of the presentinvention. In the illustrated embodiment, the cushion to frame assemblymechanism includes a slide-on frame clip 12 that is adapted to removablyconnect the frame 14 to the cushion 16.

Specifically, the frame 14 includes a main body that provides an opening18 for communicating with an inlet conduit. At least a portion of theframe perimeter includes spaced apart upper and lower retaining wallportions 20, 22. The cushion 16 (only half being shown) includes acushion wall 24 and a face-contacting portion 26, e.g., membrane. Thecushion wall 24 includes a central opening with upper and lower walls21, 23 that define an inner edge 28 (see FIG. 2B). As shown in FIG. 1,the frame 14 is received within the central opening of the cushion 16 sothat the inner edge 28 of the cushion 16 is received between the upperand lower retaining wall portions 20, 22 of the frame 14. This partiallysecures the cushion 16 to the frame 14 to provide a cushion/framesub-assembly 30. A slide-on frame clip 12 is engaged with thesub-assembly 30 to maintain engagement between the frame 14 and cushion16.

As illustrated, the frame clip 12 has a U-shaped configuration thatprovides upper and lower retaining wall portions 32, 34. The frame clip12 is slid onto the sub-assembly 30 such that the upper and lowerretaining wall portions 32, 34 straddle the upper wall portion 20 of theframe 14. In addition, the lower wall portion 34 of the frame clip 12sandwiches the U-shaped recess formed by the upper and lower walls 21,23 of the inner edge 28 of the cushion 16 against the correspondingU-shaped configuration formed by the upper wall portion 20 and lowerwall portion 22 of the frame 14 (see FIG. 2B). This arrangement providesa compressive force into the cushion 16 (in the direction of the arrowshown in FIG. 2B). Further, as shown in FIG. 2, the frame clip 12provides support wings 36 that support the cushion wall 24 in use.

In an embodiment, the frame 14 and frame clip 12 may be constructed ofpolycarbonate and the cushion 16 may be constructed of liquid siliconerubber (LSR). However, other suitable materials may be used.

In an embodiment, the frame 14 could potentially be over-molded withcushion 16, thereby negating the need for frame clip 12.

2. Second Embodiment of Cushion to Frame Assembly Mechanism

FIGS. 3 and 4 illustrate a mask assembly 210 including a cushion toframe assembly mechanism according to another embodiment of the presentinvention. In the illustrated embodiment, the cushion to frame assemblymechanism includes a skeleton frame 212 that is adapted to removablyinterlock with a cushion/frame sub-assembly 230.

Specifically, a frame and a cushion are integrally molded in one-pieceto provide a cushion/frame sub-assembly 230. In an embodiment, thecushion/frame sub-assembly 230 may be constructed of liquid siliconerubber (LSR). However, other suitable materials may be used.

The cushion/frame sub-assembly 230 includes an upper wall 220 thatprovides an opening 218 for communicating with an inlet conduit. Anannular wall 240 surrounds the opening 218. A side wall 224 extends fromthe upper wall 220 and leads to a face contacting portion 226. In anembodiment, the face contacting portion 226 has a double wallconstruction, e.g., membrane and underlying support cushion. The sidewall 224 includes elongated protrusions 242 that extend around theperimeter of the cushion/frame sub-assembly 230. In the illustratedembodiment, the side wall 224 includes three spaced apart elongatedprotrusions 242 (only two being visible). However, the side wall 224 mayinclude one continuous protrusion, or any suitable number of spacedapart protrusions.

The skeleton frame 212 includes an upper support member 244 adapted tosupport a forehead support, lower headgear clip receptacles 246 adaptedto be engaged with clips provided to straps of a headgear assembly (notshown), and an annular elbow connection seal 248 adapted to engage aninlet conduit, e.g., elbow. The upper support member 244 and clipreceptacles 246 are interconnected via elongated frame members 250. Inthe illustrated embodiment, the skeleton frame 212 is formed of plasticand has an integral one-piece construction.

As shown in FIG. 4, the skeleton frame 212 is engaged with thecushion/frame sub-assembly 230 such that the annular elbow connectionseal 248 interlocks with the annular wall 240 of the cushion/framesub-assembly 230, the upper support member 244 interlocks or isfrictionally engaged with a top portion 231 of the cushion/framesub-assembly 230, and the elongated frame members 250 interlock withrespective protrusions 242 provided around the perimeter of thecushion/frame sub-assembly 230. The skeleton frame 212 adds rigidity tothe cushion/frame sub-assembly 230 and provides attachment points for aforehead support, a headgear assembly, and an inlet conduit.

FIG. 5 illustrates a mask assembly 310 including a cushion to frameassembly mechanism according to another embodiment of the presentinvention. Similar to the above embodiment, the cushion to frameassembly mechanism includes a skeleton frame 312 that is adapted toremovably interlock with a one-piece integrally molded cushion/framesub-assembly 330.

As illustrated, each side wall 324 of the cushion/frame sub-assembly 330includes a protrusion 341 and an elongated extension 342 that provides aslot 343. The skeleton frame 312 includes elongated frame members 350that each include a tab 351. The skeleton frame 312 is engaged with thecushion/frame sub-assembly 330 such that the tabs 351 are receivedwithin respective slots 343 of the cushion/frame sub-assembly 330, andthe elongated frame members 350 interlock with respective protrusions341 provided on the perimeter of the cushion/frame sub-assembly 330.When interlocked, the tabs 351 provide support to the face contactingportion 326, e.g., membrane and underlying support cushion, of thecushion 316.

Also, the skeleton frame 312 and/or cushion/frame sub-assembly 330 isdesigned such that the tool core is along a single line of draw(indicated by the arrow).

In an embodiment, the cushion/frame sub-assembly 230, 330 couldpotentially be over-molded with the skeleton frame 212, 312.

3. Third Embodiment of Cushion to Frame Assembly Mechanism

FIGS. 6-8 illustrate a mask assembly 410 including a cushion to frameassembly mechanism according to another embodiment of the presentinvention. In the illustrated embodiment, the cushion to frame assemblymechanism includes a skeleton frame 412 that is adapted to removablyinterlock with a cushion/frame sub-assembly 430.

Specifically, a frame 414 and a cushion 416 are formed separately fromone another and then interlocked to provide a cushion/frame sub-assembly430. As shown in FIG. 6, the cushion 416 includes a side wall 424 and aface contacting portion 426 extending from the side wall 424. In anembodiment, the face contacting portion 426 has a double wallconstruction, e.g., membrane and underlying support cushion. Also, in anembodiment, the cushion 416 is, constructed of liquid silicone rubber(LSR). However, other suitable materials may be used.

The frame 414 includes an upper wall that provides an opening 418 forcommunicating with an inlet conduit. An annular wall 440 surrounds theopening 418. A side wall 420 extends from the upper wall and includeselongated protrusions 442 that extend around the perimeter thereof. Inthe illustrated embodiment, the side wall 420 includes three spacedapart elongated protrusions 442 (only two being visible). However, theside wall 420 may include one continuous protrusion, or any suitablenumber of spaced apart protrusions. In an embodiment, the frame 414 isconstructed of polycarbonate.

As shown in FIG. 7, the cushion 416 is interlocked with the frame 414 toprovide the cushion/frame sub-assembly 430. The cushion 416 may beinterlocked with the frame 414 in any suitable manner, e.g., mechanicalinterlock, etc.

As best shown in FIGS. 6 and 7, the skeleton frame 412 includes an uppersupport member 444 adapted to support a forehead support, lower headgearclip receptacles 446 adapted to be engaged with clips provided to strapsof a headgear assembly (not shown), and an annular elbow connection seal448 adapted to engage an inlet conduit, e.g., elbow. The upper supportmember 444 and clip receptacles 446 are interconnected via elongatedframe members 450. In the illustrated embodiment, the skeleton frame 412is formed of plastic and has an integral one-piece construction.

As shown in FIG. 8, the skeleton frame 412 is engaged with thecushion/frame sub-assembly 430 such that the annular elbow connectionseal 448 interlocks with the annular wall 440 of the cushion/framesub-assembly 430, the upper support member 444 interlocks with a topportion 431 of the cushion/frame sub-assembly 430, and the elongatedframe members 450 interlock with respective protrusions 442 providedaround the perimeter of the cushion/frame sub-assembly 430. The skeletonframe 412 adds rigidity to the cushion/frame sub-assembly 430 andprovides attachment points for a forehead support, a headgear assembly,and an inlet conduit.

FIG. 9 illustrates a mask assembly 510 including a cushion to frameassembly mechanism according to another embodiment of the presentinvention. Similar to the above embodiment, the cushion to frameassembly mechanism includes a skeleton frame 512 that is adapted toremovably interlock with a separately formed and interlockedcushion/frame sub-assembly 530.

The skeleton frame 512 is interlocked with the cushion/framesub-assembly 530 via snap-fit clips 552. As illustrated, when theskeleton frame 512 is interlocked with the cushion/frame sub-assembly530, the elongated frame members 550 of the skeleton frame 512 trap thecushion 516 to the frame 514. That is, the skeleton frame 512 and theframe side wall 520 sandwich the cushion side wall 524 to secure thecushion 516 to the frame 514.

In an embodiment, the frame 414 could potentially be over-molded withthe cushion 416. Also, the cushion/frame sub-assembly 430, 530 couldpotentially be over-molded with the skeleton frame 412, 512.

4. Fourth Embodiment of Cushion to Frame Assembly Mechanism

FIGS. 10-11 illustrate a mask assembly 610 including a cushion to frameassembly mechanism according to another embodiment of the presentinvention. In the illustrated embodiment, the cushion to frame assemblymechanism includes a cushion 616 with integrally molded hooks 652 thatare adapted to removably interlock and/or engage with features moldedonto the frame 614.

As shown in FIG. 10, the cushion 616 includes a side wall 624 and a facecontacting portion 626 extending from the side wall 624. In anembodiment, the face contacting portion 626 has a double wallconstruction, e.g., membrane and underlying support cushion. Also, in anembodiment, the cushion 626 is constructed of liquid silicone rubber(LSR). However, other suitable materials may be used. As illustrated,interlocking members in the form of hooks 652 protrude from the sidewalls 624. In the illustrated embodiment, four hooks 652 are provided.However, the cushion 616 may include any suitable number of hooks 652.

The frame 614 includes an upper support member 644 adapted to support aforehead support, lower headgear clip receptacles 646 adapted to beengaged with clips provided to straps of a headgear assembly (notshown), and an annular elbow connection seal 648 adapted to engage aninlet conduit, e.g., elbow. Also, the frame side wall 620 includes aseries of recesses 621 around the perimeter thereof. In the illustratedembodiment, the side wall 620 includes the same number of recesses 621as hooks 652 on the cushion 616, e.g., four. In an embodiment, the frame614 is molded in one-piece with polycarbonate and the recesses 651 areintegrally molded into the frame 614.

As shown in FIG. 11, the cushion 616 is engaged with the frame 614 suchthat the hooks 652 interlock with respective recesses 621 providedaround the perimeter of the frame 614, e.g., with a friction fit. In anembodiment, each recess 621 may provide a projection adapted to extendthrough a respective hook 652 to facilitate attachment of the cushion616. Further, the cushion 616 includes an additional projection 656 thatengages with an additional recess 657 provided on the frame 614. Theadditional projection 656/recess 657 may facilitate alignment and/orinterlocking engagement between the cushion 616 and the frame 614.

FIGS. 12 and 13 illustrate a mask assembly 710 including a cushion toframe assembly mechanism according to another embodiment of the presentinvention. Similar to the above embodiment, the cushion to frameassembly mechanism includes a cushion 716 with integrally molded tabs752 that are adapted to removably interlock with locking features moldedonto the frame 714.

As illustrated, each side wall 724 of the cushion 716 includes aprotruding tab 752 that defines an opening 753. In addition, each sidewall 724 includes a first locking member 760 that extends along thelength thereof. The frame 714 includes a protrusion 754 on opposite sidewalls 720 thereof. In addition, the side walls 720 each include a secondlocking member 762 that extends along the length thereof.

As shown in FIG. 13, the cushion 716 is engaged with the frame 714 suchthat the tabs 752 interlock with respective protrusions 754 provided onthe frame 714. Specifically, the tabs 752 are pulled over respectiveprotrusions 754 until the protrusions 754 protrude through respectiveopenings 753 in the tabs 752. In addition, the first locking member 760interlocks with the second locking member 762 to further secure thecushion 716 to the frame 714 and provide a seal. As illustrated, thefirst locking member 760 includes an elongated resiliently flexible lip770 is adapted to engage the lower edge of the frame 714. The lip 770 isresiliently flexible so that it provides a pressure assisted seal inuse.

In an embodiment, the frame 614 could potentially be over-molded withthe cushion 616, thereby negating the need for frame recesses 621 andrespective cushion hooks 652. Also, the frame 714 could potentially beover-molded with the cushion 716, thereby negating the need for frameprotrusions 754 and respective cushion protruding tabs 752.

5. Fifth Embodiment of Cushion to Frame Assembly Mechanism

FIGS. 14-17 illustrate a mask assembly 810 including a cushion to frameassembly mechanism according to another embodiment of the presentinvention. In the illustrated embodiment, the cushion to frame assemblymechanism includes a frame clip 812 and fold-over clips 852 that areadapted to removably connect the frame 814 to the cushion 816.

As shown in FIG. 14, the cushion 816 includes a side wall 824 and a facecontacting portion 826 extending from the side wall 824. In anembodiment, the face contacting portion 826 has a double wallconstruction, e.g., membrane and underlying support cushion. Also, in anembodiment, the cushion 816 is constructed of liquid silicone rubber(LSR). However, other suitable materials may be used. As illustrated, aflange 828 protrudes outwardly from the side wall 824 around theperimeter thereof. A recess 829 is provided in a portion of the flange828.

The frame 814 includes an upper support member 844 adapted to support aforehead support, lower headgear clip receptacles 846 (FIG. 16) adaptedto be engaged with clips provided to straps of a headgear assembly (notshown), and an annular elbow connection seal 848 adapted to engage aninlet conduit, e.g., elbow. Also, the frame side wall 820 includes aflange 840 around a portion of the perimeter thereof. A recess 842 isprovided in a portion of the flange 840. Further, latching features 843,e.g., two recessed portions, are provided on the flange 840. In anembodiment, the frame 814 is molded in one-piece with polycarbonate andthe latching features 843 are integrally molded into the frame 814.

The frame clip 812, e.g., molded of plastic, has a hoop-likeconfiguration that generally corresponds in shape to the cushion 816 andframe 814, e.g., generally triangular. A projection 856 is provided in aportion of the frame clip 812.

Fold-over clips 852, e.g., molded of plastic, are provided tointerconnect the frame clip 812, cushion 816, and frame 814. Thefold-over clips 852 may be molded separately from the frame clip 812 andthen assembled thereto. Alternatively, the fold-over clips 852 may beintegrally molded onto the frame clip 812. As illustrated, two fold-overclips 852 are provided. However, other suitable numbers of fold-overclips may be used, e.g., more than two, to interconnect the frame clip812, cushion 816, and frame 814.

As shown in FIG. 15, the frame clip 812 is engaged with the cushion 816so that it extends around the cushion perimeter and abuts the flange828. In addition, the projection 856 of the frame clip 812 extendsthrough the recess 829 to facilitate alignment. Further, the fold-overclips 852 (if formed separately from the frame clip 812) each include afirst latching end 853 (see FIG. 14) that is adapted to engage the frameclip 812 at a position that will align with a respective latchingfeature 843 of the frame 814.

As shown in FIG. 16, the frame 814 is engaged with the cushion 816/frameclip 812/fold-over clip 852 sub-assembly such that the projection 856 ofthe frame clip 812 extends through the recess 842 in the frame 814.Then, the fold-over clips 852 are folded over so that they engage orlatch onto respective latching features 843 provided on the frame 814.FIG. 17 illustrates the assembled mask assembly 810.

In the illustrated embodiment, the frame clip 812 is assembled from thebottom, e.g., cushion side, and the fold-over clips 852 latch ontolatching features 843 molded onto the frame 814. In another embodiment,the frame clip 812 may be assembled from the top, e.g., frame side, andthe fold-over clips 852 may latch onto latching features molded onto thecushion 816.

As described above, the cushion 816 may include a resiliently flexiblelip that is adapted to engage the frame 814 to provide a pressureassisted seal in use.

In an embodiment, the frame clip 812 may be over-molded with the cushion816. In another embodiment, the fold-over clips 852 may be integrallymolded with the frame 814 (inverse configuration from that shown, i.e.,the fold-over clips 852 would latch onto the cushion 816).

6. Sixth Embodiment of Cushion to Frame Assembly Mechanism

FIGS. 18-20 illustrate a mask assembly 910 including a cushion to frameassembly mechanism according to another embodiment of the presentinvention. In the illustrated embodiment, the cushion to frame assemblymechanism includes a cushion clip 912 that is adapted to removablyconnect the cushion 916 to the frame 914.

As shown in FIG. 18, the cushion 916 includes a side wall 924 and a facecontacting portion 926 extending from the side wall 924. In anembodiment, the face contacting portion 926 has a double wallconstruction, e.g., membrane and underlying support cushion. Also, in anembodiment, the cushion 916 is constructed of liquid silicone rubber(LSR). However, other suitable materials may be used. As illustrated, aflange 928 protrudes inwardly from the side wall 924 around theperimeter thereof.

The frame 914 includes an upper support member 944 adapted to support aforehead support, lower headgear clip receptacles 946 adapted to beengaged with clips provided to straps of a headgear assembly (notshown), and an annular elbow connection seal 948 adapted to engage aninlet conduit, e.g., elbow. Also, the top wall of the frame 914 includesa plurality of slots 942 therethrough, e.g., three slots. In anembodiment, the frame 914 is molded in one-piece with polycarbonate,e.g., clear polycarbonate.

The cushion clip 912, e.g., molded of plastic, has a hoop-likeconfiguration that generally corresponds in shape to the cushion 916 andframe 914, e.g., generally triangular. One or more flange portions 950are provided around the perimeter of the cushion clip 912. Also, thecushion clip 912 includes a plurality of clip portions 952. Asillustrated, the cushion clip 912 includes the same number of clipportions 952 as slots 942 on the frame 914, e.g., three clip portions.

As shown in FIG. 19, the cushion clip 912 is first assembled orinterlocked with the cushion 916 to provide a cushion clip/cushionsub-assembly 980; Specifically, the cushion 916 is assembled around thecushion clip 912 by engaging the flange portions 950 of the cushion clip912 with the flange 928 of the cushion 916. The cushion clip/cushionsub-assembly 980 is engaged with the frame 914 by inserting the clipportions 952 of the cushion clip 912 into respective slots 942 of theframe 914. The clip portions 952 are adapted to engage respective slots942 with a snap-fit. FIG. 20 illustrates the assembled mask assembly 910with the cushion clip/cushion sub-assembly 980 retained at threeperimeter points on the frame 914.

As described above, the cushion 916 may include a resiliently flexiblelip that is adapted to engage the frame 914 to provide a pressureassisted seal in use.

Also, as shown in FIG. 21, the cushion 916 may have tab features 966 ona cushion lip thereof to facilitate easier assembly of the cushion clip912.

In an embodiment, the cushion clip 912 may be over-molded with thecushion 916.

7. Seventh Embodiment of Cushion to Frame Assembly Mechanism

FIGS. 22-26 illustrate a mask assembly 1010 including a cushion to frameassembly mechanism according to another embodiment of the presentinvention. In the illustrated embodiment, the cushion to frame assemblymechanism includes a pressure assisted lip seal design.

As best shown in FIGS. 22-23, the cushion 1016 includes a side wall1024, a face-contacting portion 1026, and a non-face-contacting portion1027. In the illustrated embodiment, the face-contacting portion 1026has a double wall construction, e.g., membrane and underlying supportcushion. The non-face-contacting portion 1027 provides a frameconnection. Specifically, the non-face-contacting portion 1027 includesinner and outer 1032, 1034 that define a retaining recess 1036 aroundthe perimeter of the cushion 1016. In addition, the non-face-contactingportion 1027 provides an elongated resiliently flexible lip 1070 that isadapted to engage the frame 1014 to provide a pressure assisted seal inuse. As shown in FIG. 22, the lip 1070 has a non-planar trajectory orconfiguration. In an embodiment, the lip 1070 has a length of 4-12 mm,preferably 8 mm, and a width of 0.25-1.25, preferably 0.75 mm. However,other dimensions are possible depending on application. Also, in anembodiment, the cushion 1016 is constructed of liquid silicone rubber(LSR). However, other suitable materials may be used.

As shown in FIGS. 24-26, the frame 1014 includes an annular elbowconnection seal 1048 adapted to engage an inlet conduit, e.g., elbow.Also, the frame 1014 provides a cushion connection including an outerwall 1020 and an inner wall 1022 that extend around the perimeter of theframe 1014. In an embodiment, the frame 1014 is molded in one-piece withpolycarbonate.

As shown in FIG. 24, the cushion 1016 is engaged with the frame 1014 toprovide a cushion/frame sub-assembly 1030. Specifically, the outer wall1020 of the frame 1014 is inserted into the retaining recess 1036 of thecushion 1016, e.g., with a friction fit. In addition, the lip 1070 ofthe cushion 1016 resiliently engages the inner wall 1022 of the frame1014 to provide a seal in use.

As shown in FIGS. 25 and 26, a cushion clip 1012, e.g., molded ofplastic, is provided to maintain engagement between the frame 1014 andthe cushion 1016. As illustrated, the cushion clip 1012 includes a firstretaining portion 1060 that provides a shoulder for engaging the frame1014 and a second retaining portion 1062 that provides a shoulder forengaging the cushion 1016. Thus, the cushion clip 1012 sandwiches theframe 1014 and the cushion 1016 to maintain their engagement.

In an embodiment, the frame clip 1012 may be over-molded with thecushion 1016. In another embodiment, the frame 1014 may be over-moldedwith the cushion 1016, thereby negating the need for the frame clip1012.

FIGS. 27 and 28 illustrate a cushion to frame assembly mechanismaccording to another embodiment of the present invention. Asillustrated, the frame 1114 provides a cushion connection including aside wall 1120 and an upper wall 1132 and a lower wall 1134 that extendaround the perimeter of the side wall 1120. In the illustratedembodiment, the upper and lower walls 1132, 1134 are inclined such thatthe walls 1120, 1132, 1134 define a generally k-shaped cross-sectionalconfiguration.

As shown in FIG. 28, the non-face-contacting portion 1127 of the cushion1116 includes a retaining wall 1124 that is inclined towards the cushioninterior. As illustrated, the end 1125 of the retaining wall 1124 has anangled or pointed configuration. In addition, the non-face-contactingportion 1127 provides an elongated resiliently flexible lip 1170.

The cushion 1116 is engaged with the frame 1114 by stretching thecushion 1116 over the frame perimeter such that the retaining wall 1124engages within the retaining recess 1136 defined between the upper andlower walls 1132, 1134. As illustrated, the angled or pointed end 1125of the retaining wall 1124 conforms to the incline defined by the upperand lower walls 1132, 1134. In addition, the lip 1170 of the cushion1116 resiliently engages the inner end of the frame side wall 1120 toprovide a seal in use. A cushion clip (not shown) may be provided, e.g.,around the cushion perimeter, to maintain engagement between the frame1114 and the cushion 1116.

In an embodiment, the frame 1114 could potentially be over-molded withthe cushion 1116, thereby negating need for a cushion clip.

8. Eighth Embodiment of Cushion to Frame Assembly Mechanism

FIGS. 29-32 illustrate a mask assembly 1210 including a cushion to frameassembly mechanism according to another embodiment of the presentinvention. In the illustrated embodiment, the cushion to frame assemblymechanism includes an integrated lip seal design.

As illustrated, the frame 1214 includes an annular elbow connection seal1248 adapted to engage an inlet conduit, e.g., elbow. Also, the frame1214 provides a cushion connection including an outer wall 1220 and aninner wall 1222 that extend around the perimeter of the frame 1214. Theouter and inner walls 1220, 1222 define a retaining recess 1236therebetween. In an embodiment, the frame 1214 is molded in one-piecewith polycarbonate.

The non-face-contacting portion 1227 of the cushion 1216 includes aretaining portion 1260. As illustrated, the end 1261 of the retainingportion 1260 has an angled or pointed configuration. In addition, thenon-face-contacting portion 1227 provides a resiliently flexible lip1270. A space 1271 is provided behind the lip 1270 to provide the lip1270 with a range of movement in use.

As shown in FIGS. 30 and 32, the frame 1214 is engaged with the cushion1216 such that the retaining portion 1260 of the cushion 1216 engageswithin the retaining recess 1236 defined between the outer and innerwalls 1220, 1222. As illustrated, the angled or pointed end 1261 of theretaining portion 1260 conforms to the incline defined by the outer andinner walls 1220, 1222. In addition, the lip 1270 of the cushion 1216resiliently engages the inner wall 1222 of the frame 1214 to provide aseal in use. The lip 1270 may deflect inwardly into the space 1271,against resiliency thereof, to provide the seal. Also, as shown in FIG.30, a pressure line 1276 may be incorporated into the flange perimeterof the frame 1214 and cushion 1216.

A frame clip may be provided to maintain engagement between the frame1214 and the cushion 1216. The frame clip may be assembled from thebottom, e.g., cushion side, or the frame clip may be assembled from thetop, e.g., frame side.

FIGS. 33-34 illustrate a bottom assembling frame clip 1312. Asillustrated, the frame clip 1312, e.g., molded of plastic, is assembledover the cushion 1216 and includes a first retaining portion 1375 thatprovides a shoulder for engaging the cushion flange 1254 and a pluralityof second retaining portions 1377 that provide a shoulder for engagingthe frame 1214. Thus, the frame clip 1312 sandwiches the frame 1214 andthe cushion 1216 to maintain their engagement.

In an embodiment, the frame clip 1312 may be over-molded with thecushion 1216. In another embodiment, the frame 1214 may be over-moldedwith the cushion 1216, thereby negating the need for the frame clip1312.

FIGS. 35-39 illustrate a top assembling frame clip 1412. Similar to theabove, the frame 1214 is engaged with the cushion 1216 such that theretaining portion 1260 of the cushion 1216 engages within the retainingrecess 1236 defined between the outer and inner walls 1220, 1222 (seeFIGS. 35-36). FIG. 38 illustrates a portion of the cushion 1216 to showthe retaining portion 1260, the lip 1270, and the face-contactingportion 1226 thereof. FIG. 38 also illustrates an undercut region 1266in the cushion 1216 that defines the cushion flange 1254.

The frame clip 1412, e.g., molded of plastic, is assembled over theframe 1214 and includes a first retaining portion 1475 that provides ashoulder for engaging the frame 1214 and a plurality of second retainingportions 1477, e.g., three retaining portions, that provide a shoulderfor engaging the cushion flange 1254, as shown in FIGS. 36, 37, and 39.Thus, the frame clip 1412 sandwiches the frame 1214 and the cushion 1216to maintain their engagement as best shown in FIG. 39.

In an embodiment, the frame 1214 could potentially be over-molded withthe cushion 1216, thereby negating the need for the frame clip 1412.

In an alternative embodiment, as shown in FIG. 40, the inner wall 1222of the frame 1214 may include a protrusion 1223 along the perimeterthereof. The protrusion 1223 provides interference with the cushion 1216in use, thereby preventing inadvertent removal of the cushion 1216 fromthe frame 1214. Moreover, the protrusion 1223 may provide sufficientinterference to avoid the need for a frame clip.

FIGS. 41-44 illustrate another cushion to frame assembly mechanismincluding a cushion clip 1512 for use with a cushion 1516 having anintegrated lip seal. As illustrated, the non-face-contacting portion1527 of the cushion 1516 includes a retaining recess 1536 around theperimeter thereof that is adapted to engage the cushion clip 1512.Specifically, the cushion clip 1512, e.g., molded of plastic, includesone or more flange portions 1550 around the perimeter thereof that areengaged within the retaining recess 1536 of the cushion 1516 to providea cushion clip/cushion sub-assembly 1580.

The cushion clip/cushion sub-assembly 1580 is then engaged with theframe 1514 by inserting the clip portions 1552, e.g., three clipportions, of the cushion clip 1512 into respective slots 1542 of theframe 1514. The clip portions 1552 are adapted to engage respectiveslots 1542 with a snap-fit. FIG. 44 illustrates the assembled maskassembly 1510 with the cushion clip/cushion sub-assembly 1580 retainedon the frame 1514. As illustrated, the lip 1570 of the cushion 1516resiliently engages the inner wall 1520 of the frame 1514 to provide aseal in use.

In an embodiment, the cushion clip 1512 could potentially be over-moldedwith the cushion 1516.

9. Ninth Embodiment of Cushion to Frame Assembly Mechanism

FIGS. 45 and 46 illustrate a mask assembly 1610 including a cushion toframe assembly mechanism according to another embodiment of the presentinvention. In the illustrated embodiment, the cushion to frame assemblymechanism includes a slide-on two-part frame clip 1612 that is adaptedto removably connect the cushion 1616 to the frame 1614.

As shown in FIG. 45, the cushion 1616 includes a side wall 1624 and aface contacting portion 1626 extending from the side wall 1624. In anembodiment, the face contacting portion 1626 may have a double wallconstruction, e.g., membrane and underlying support cushion. Also, in anembodiment, the cushion 1616 is constructed of liquid silicone rubber(LSR). However, other suitable materials may be used. As illustrated, aflange 1628 protrudes inwardly from the side wall 1624 around theperimeter thereof.

The frame 1614 includes an opening 1648 that is communicated with aninlet conduit. Also, the frame 1614 provides a flange 1620 that extendsaround the perimeter of the frame 1614. In an embodiment, the frame 1614is molded in one-piece with polycarbonate.

The slide-on two-part frame clip 1612 includes a first part 1632 and asecond part 1634 attachable to the first part 1632, e.g., with asnap-fit. The first part 1632 includes an upper support member 1644adapted to support a forehead support and an annular elbow connectionseal 1649 adapted to engage an inlet conduit, e.g., elbow. Also, theperimeter of the first part 1632 includes spaced apart upper and lowerwall portions 1636, 1638. The second part 1634 includes lower headgearclip receptacles 1646 adapted to be engaged with clips provided tostraps of a headgear assembly (not shown) and retaining members 1647adapted to interlock with the first part 1632. Also, the perimeter ofthe second part 1634 includes spaced apart upper and lower wall portions(not shown). In an embodiment, the first and second parts 1632, 1634 ofthe frame clip 1612 are molded with polycarbonate.

The cushion 1616 is first engaged with the frame 1614 to provide acushion/frame sub-assembly. Specifically, the side wall 1624 of thecushion 1616 is engaged with the side wall of the frame 1614, e.g., witha friction fit, such that the cushion flange 1628 engages against theframe flange 1620 (see FIG. 46).

Then, the first part 1632 of the frame clip 1612 is slid onto one sideof the cushion/frame sub-assembly and the second part 1634 is slid ontothe opposite side of the cushion/frame sub-assembly such that the upperand lower wall portions 1636, 1638 of the first and second parts 1632,1634 sandwich the cushion flange 1628 and the frame flange 1620therebetween (see FIG. 46). The first and second parts 1632, 1634 areslid towards one another until the retaining members 1647 of the secondpart 1634 interlock with the first part 1632, e.g., with a snap-fit.Thus, the first and second parts 1632, 1634 sandwich the frame 1614 andthe cushion 1616 to maintain their engagement. The upper and lower wallportions 1636, 1638 of the first and second parts 1632, 1634 provide acompression seal in use.

FIGS. 47-49 illustrate a mask assembly substantially similar to the maskassembly 1610 described above. Therefore, similar components areindicated with similar reference numerals. In contrast, the second part1634 includes lower headgear cross-bars 1746 adapted to be engaged withstraps of a headgear assembly (not shown). Also, an inner frame memberprovided between the cushion 1616 and frame clip 1612 is not shown.

In each embodiment, the cushion to frame assembly mechanism provides aflat or radial slide path.

In an embodiment, the frame 1614 and cushion 1616 may be integrallymolded in one-piece, e.g., with LSR, to provide a one-piececushion/frame sub-assembly.

FIGS. 50-51 illustrate alternative frame clip designs. FIG. 50illustrates an over-center clip 1812 having a plurality of hinged links1813, e.g., three links, that can be pivoted to secure the clip 1812 inplace. FIG. 51 illustrates a ratchet clip 1912 having arms 1913, 1915that are pivotable about hinge point P. The arms 1913, 1915 have toothedend portions 1917, 1919 that interlock to secure the clip 1912 in place.

10. Tenth Embodiment of Cushion to Frame Assembly Mechanism

FIGS. 52-71 illustrate a mask assembly 2010 including a cushion to frameassembly mechanism according to another embodiment of the presentinvention. In the illustrated embodiment, the cushion to frame assemblymechanism includes a cushion clip 2012 that is adapted to removablyconnect the cushion 2016 to the frame 2014.

As shown in FIGS. 52-55 and 62-66, the cushion 2016 includes aface-contacting portion 2026 and a non-face-contacting portion 2027. Inan embodiment, the face contacting portion 2026 has a double wallconstruction, e.g., membrane and underlying support cushion. Also, in anembodiment, the cushion 2016 is constructed of liquid silicone rubber(LSR). However, other suitable materials may be used. As illustrated,the non-face-contacting portion 2027 of the cushion 2016 includes aretaining recess 2036 around the perimeter thereof that is adapted toengage the cushion clip 2012.

As shown in FIGS. 52-61, the frame 2014 includes an upper support member2044 adapted to support a forehead support, lower headgear clipreceptacles 2046 adapted to be engaged with clips provided to straps ofa headgear assembly (not shown), and an annular elbow connection seal2048 adapted to engage an inlet conduit, e.g., elbow. Also, the top wallof the frame 2014 includes a plurality of slots 2042 therethrough, e.g.,three slots. In an embodiment, the frame 2014 is molded in one-piecewith polycarbonate.

As shown in FIGS. 52-56 and 67-71, the cushion clip 2012, e.g., moldedof plastic, has a hoop-like configuration that generally corresponds inshape to the cushion 2016 and frame 2014, e.g., generally triangular. Inaddition, the cushion clip 2012 is contoured to match the contour of theframe 2014 and cushion 2016. One or more flange portions 2050 areprovided around the perimeter of the cushion clip 2012. Also, thecushion clip 2012 includes a plurality of clip portions 2052. Asillustrated, the cushion clip 2012 includes the same number of clipportions 2052 as slots 2042 on the frame 2014, e.g., three clipportions.

As shown in FIG. 53, the cushion clip 2012 is first assembled orinterlocked with the cushion 2016 to provide a cushion clip/cushionsub-assembly 2080. Specifically, the cushion 2016 is assembled aroundthe cushion clip 2012 by engaging the flange portions 2050 of thecushion clip 2012 within the retaining recess 2036 of the cushion 2016.The cushion clip/cushion sub-assembly 2080 is then engaged with theframe 2014 by inserting the clip portions 2052 of the cushion clip 2012into respective slots 2042 of the frame 2014. The clip portions 2052 areadapted to engage respective slots 2042 with a snap-fit. FIG. 54-56illustrate the assembled mask assembly 2010 with the cushionclip/cushion sub-assembly 2080 retained at three perimeter points on theframe 2014.

As best shown in FIGS. 52, 63B, 64, and 70, the cushion clip 2012includes slots 2013 on opposing sides thereof, i.e., created by breaksin the flange portions 2050, that interlock or engage with respectivesolid sections 2037 provided in the retaining recess 2036 on opposingsides of the cushion 2016. The two solid sections 2037 assist with thecorrect orientation or alignment of the cushion clip 2012 onto thecushion 2016.

As best shown in FIGS. 55 and 66, the cushion 2016 includes aresiliently flexible lip 2070 that resiliently engages the inner wall2020 of the frame 2014 to provide a seal in use. Also, the cushion 2016includes finger grips 2092 on a flange portion thereof to facilitateassembly (e.g., see FIGS. 62, 65, and 66).

The clip portions 2052 of the cushion clip 2012 include contoured fingergrips 2094 to facilitate assembly. As illustrated, the finger grips 2094are relatively thick for ease of finding and use.

FIGS. 92-105 illustrate a mask assembly substantially similar to themask assembly 2010 described above. Therefore, similar components areindicated with similar reference numerals. In contrast, the cushion clip2012 of FIGS. 92-105 includes a continuous flange 2050 that extends orruns around the entire perimeter of the cushion clip 2012. Thus, thecushion clip 2012 of FIGS. 92-105 does not include any slots along theflange 2050, and the two solid sections in the cushion retaining recessof the cushion shown in FIGS. 52-71 may be removed. Removal of theinterlocking feature, i.e., slot of clip interlocked with solid sectionof cushion, provides more support to the cushion 2016 to prevent leakbetween the cushion and the frame. The continuous flange 2050 of FIGS.92-105 also makes the cushion clip 2012 stiffer.

FIGS. 55 and 95 illustrate the assembled cushion 2016, cushion clip2012, and frame 2014 at top and bottom portions of the mask assembly.FIGS. 106 and 107 illustrate an alternative embodiment at top and bottomportions of the mask assembly. For example, the top wall 2001 of theframe 2014 at top and bottom portions thereof may have a steeper angleor incline for styling or aesthetics purposes. Also, the exterior orouter surface 2017 of the cushion 2016 may be angled or inclined. Theinclined outer surface 2017 varies the gap or distance between the outersurface 2017 and the inner surface of the frame side wall 2003. This mayfacilitate reduction of the possible movement range between the cushion2016 and the frame wall 2003, which in turn reduces system leakage underside loading.

In each of the embodiments, the cushion clip 2012 could potentially beover-molded with the cushion 2016.

11. Eleventh Embodiment of Cushion to Frame Assembly Mechanism

FIGS. 72-91 illustrate a mask assembly 2110 including a cushion to frameassembly mechanism according to another embodiment of the presentinvention. In the illustrated embodiment, the cushion to frame assemblymechanism includes an integrated lip seal design and a frame clip 2112that is adapted to removably connect the cushion 2116 to the frame 2114.

As shown in FIGS. 72-81, the frame 2114 includes an upper support member2144 adapted to support a forehead support, lower headgear clipreceptacles 2146 adapted to be engaged with clips provided to straps ofa headgear assembly (not shown), and an annular elbow connection seal2148 adapted to engage an inlet conduit, e.g., elbow. Also, the frame2114 provides a cushion connection including an outer wall 2120 and aninner wall 2122 that extend around the perimeter of the frame 2114. Theouter and inner walls 2120, 2122 define a retaining recess 2136therebetween. In an embodiment, the frame 2114 is molded in one-piecewith polycarbonate.

As shown in FIGS. 72-75 and 82-86, the cushion 2116 includes aface-contacting portion 2126 and a non-face-contacting portion 2127. Inan embodiment, the face contacting portion 2126 has a double wallconstruction, e.g., membrane and underlying support cushion. Also, in anembodiment, the cushion 2116 is constructed of liquid silicone rubber(LSR). However, other suitable materials may be used. Thenon-face-contacting portion 2127 of the cushion 2116 includes aretaining portion 2160. As illustrated, the end 2161 of the retainingportion 2160 has an angled or pointed configuration. In addition, thenon-face-contacting portion 2127 provides a resiliently flexible lip2170. A space 2171 is provided behind the lip 2170 to provide the lip2170 with a range of movement in use.

As shown in FIGS. 73 and 75, the frame 2114 is engaged with the cushion2116 such that the retaining portion 2160 of the cushion 2116 engageswithin the retaining recess 2136 defined between the outer and innerwalls 2120, 2122. As illustrated, the angled or pointed end 2161 of theretaining portion 2160 conforms to the incline defined by the outer andinner walls 2120, 2122. In addition, the lip 2170 of the cushion 2116resiliently engages the inner wall 2122 of the frame 2114 to provide aseal in use. The lip 2170 may deflect inwardly into the space 2171,against resiliency thereof, to provide the seal.

As shown in FIGS. 72-76 and 87-91, a bottom assembling frame clip 2112is provided to maintain engagement between the frame 2114 and thecushion 2116. The frame clip 2112 is contoured to match the contour ofthe frame 2114 and cushion 2116. As illustrated, the frame clip 2112,e.g., molded of polycarbonate, is assembled over the cushion 2116 andincludes a first retaining portion 2175 that provides a shoulder forengaging the cushion flange 2154 and a plurality of second retainingportions 2177, e.g., three retaining portions 2177, that provide ashoulder for engaging the frame 2114. Thus, the frame clip 2112sandwiches the frame 2114 and the cushion 2116 to maintain theirengagement as shown in FIGS. 74-76.

The retaining portions 2177 of the frame clip 2112 include contouredfinger grips 2194 to facilitate assembly. As illustrated, the fingergrips 2194 are relatively thick for ease of finding and use.

In the illustrated embodiment, the cushion to frame assembly mechanismincludes three retention points, e.g., three retaining portions 2177.Three retention points makes assembly time quicker and reduces theperceived (aesthetic) and actual (physical) assembly task complexity.Also, because the cushion 2116 includes the lip seal 2170, a highcompression force between the frame 2114, cushion 2116, and frame clip2112 is not required and three retaining portions 2177 are sufficientfor sealing/retaining purposes.

Also, the frame 2114 includes top hat sections 2196 that engagerespective retaining portions 2177 of the frame clip 2112 in use (e.g.,see FIGS. 72, 73, and 77-79). The top hat sections 2196 provide a visualcue or indication as to where the frame clip 2112 clips onto the frame2114, aid with alignment of the 2116 cushion onto the frame 2114 (e.g.,cushion 2116 may have integrally molded protruding sections that alignwith the top hat sections 2196 of the frame 2114), provide guide oralignment points for possible automated assembly, and provide aestheticinterest or feature to the frame 2114.

In an embodiment, the frame clip 2112 may be over-molded with thecushion 2116. In another embodiment, the frame 2114 may be over-moldedwith the cushion 2116, thereby negating the need for the frame clip2112.

While the invention has been described in connection with what arepresently considered to be the most practical and preferred embodiments,it is to be understood that the invention is not to be limited to thedisclosed embodiments, but on the contrary, is intended to cover variousmodifications and equivalent arrangements included within the spirit andscope of the invention. Also, the various embodiments described abovemay be implemented in conjunction with other embodiments, e.g., aspectsof one embodiment may be combined with aspects of another embodiment torealize yet other embodiments. In addition, while the invention hasparticular application to patients who suffer from OSA, it is to beappreciated that patients who suffer from other illnesses (e.g.,congestive heart failure, diabetes, morbid obesity, stroke, bariatricsurgery, etc.) can derive benefit from the above teachings. Moreover,the above teachings have applicability with patients and non-patientsalike in non-medical applications.

What is claimed is:
 1. A mask assembly for treatment of sleep disorderbreathing by delivering a flow of pressurized gas to a patient, the maskassembly comprising: a first frame including a first wall that at leastpartially delimits a breathing chamber, a second wall surrounding anopening through the first wall and defining a first substantiallycylindrical surface surrounding the opening and defining a central axis,the second wall extending from the first wall, the opening beingconfigured to allow the flow of pressurized gas to the breathingchamber; a second frame including a third wall that is cylindrical anddefines a second substantially cylindrical surface, a fourth wall, amember extending toward a forehead support and two headgear attachmentlocations, the third wall extending away from the fourth wall, thesecond substantially cylindrical surface at least partially overlappingwith and passing completely around the first substantially cylindricalsurface, and the second frame being configured to removably interlockwith the first frame proximate the opening when the first frame and thesecond frame are moved towards one another along the central axis; and acushion molded to the first frame and including a side wall and amembrane adapted to seal around a patient's nose, the membrane beingconnected to the side wall at an outer periphery of the membrane andbeing unconnected at an inner periphery of the membrane; wherein themembrane is on an opposite side of the first frame with respect to theopening, the first frame comprises a first material and the cushioncomprises a second material that is more flexible than the firstmaterial and the first wall and the second wall comprise the firstmaterial.
 2. The mask assembly according to claim 1, wherein the secondframe includes two second frame openings discrete from the secondsubstantially cylindrical surface and separated from the secondsubstantially cylindrical surface by at least a thickness of the thirdwall and through which the first frame is visible when the first frameand the second frame are attached to one another.
 3. The mask assemblyaccording to claim 2, wherein the opening is between the two secondframe openings.
 4. The mask assembly according to claim 1, wherein thefirst frame and the second frame are rigid and the cushion is flexible.5. The mask assembly according to claim 1, wherein the first frame andthe second frame are adapted to be interlocked while an inlet elbow isengaged with the mask assembly.
 6. The mask assembly according to claim5, wherein the inlet elbow is configured to communicate the flow ofpressurized gas through the opening.
 7. The mask assembly according toclaim 1, wherein the first frame and the second frame have mutualcontact points to prevent relative rotation of the first frame withrespect to the second frame about the opening.
 8. The mask assemblyaccording to claim 1, wherein the two headgear attachment locations areadapted to engage with clips attached to straps of a headgear assembly.9. The mask assembly according to claim 1, wherein the two headgearattachment locations are disposed adjacent to and on opposed lateralsides of the opening.
 10. The mask assembly according to claim 1,wherein the first frame and the cushion together form the breathingchamber.
 11. The mask assembly according to claim 1, wherein the openingis between two second frame openings, the first frame and the secondframe are rigid and the cushion is flexible, the first frame and thesecond frame are adapted to be interlocked while an inlet elbow isengaged with the mask assembly and the inlet elbow is configured tocommunicate the flow of pressurized gas through the opening, the twoheadgear attachment locations are adapted to engage with clips attachedto straps of a headgear assembly and are disposed adjacent to and onopposed lateral sides of the opening, the first frame and the cushiontogether form the breathing chamber.
 12. The mask assembly according toclaim 1, wherein the third wall has a thickness and a length and thelength extends substantially parallel to the central axis.
 13. The maskassembly according to claim 1, wherein the third wall extends along thecentral axis a distance that is greater than a thickness of the fourthwall.
 14. The mask assembly according to claim 1, wherein the firstsubstantially cylindrical surface and the second substantiallycylindrical surface are closely adjacent to each other.
 15. A maskassembly for treatment of sleep disorder breathing by delivering a flowof pressurized gas to a patient, the mask assembly comprising: a firstframe including a first wall that at least partially delimits abreathing chamber, a second wall surrounding an elbow opening throughthe first wall and defining a substantially cylindrical surfacesurrounding the elbow opening and defining a central axis, the secondwall extending from the first wall, the elbow opening being configuredto allow a supply of breathing gas to the breathing chamber; a secondframe including a third wall defining an annular opening, including twosecond frame openings discrete from the annular opening and throughwhich the first frame is visible when the first frame and the secondframe are attached to one another, and including two headgear attachmentlocations, the substantially cylindrical surface at least partiallyextending through and fully encircled by the annular opening, and thesecond frame being configured to removably interlock with the firstframe proximate the elbow opening when the first frame and the secondframe are moved towards one another along the central axis; and acushion attached to the first frame and including a side wall and amembrane that includes a sealing surface adapted to seal around apatient's nose, the membrane being connected to the side wall at anouter periphery of the membrane and being unconnected at an innerperiphery of the membrane; wherein the sealing surface is on an oppositeside of the first frame with respect to the elbow opening, the firstframe comprises a first material and the sealing surface comprises asecond material that is more flexible than the first material and thefirst wall and the second wall comprise the first material, a firstportion of the first frame protrudes through a first one of the twosecond frame openings and a second portion of the first frame protrudesthrough a second one of the two second frame openings, and the firstframe and the second frame have mutual contact points to preventrelative rotation of the first frame with respect to the second frameabout the opening.
 16. The mask assembly according to claim 15, whereinthe cushion is removably attached to the first frame.
 17. The maskassembly according to claim 15, wherein the opening is between the twosecond frame openings.
 18. The mask assembly according to claim 15,wherein the first frame and the second frame are adapted to beinterlocked while an inlet elbow is engaged with the mask assembly. 19.The mask assembly according to claim 18, wherein the inlet elbow isconfigured to communicate the supply of breathing gas through theopening.
 20. The mask assembly according to claim 15, wherein the twoheadgear attachment locations are adapted to engage with clips attachedto straps of a headgear assembly.
 21. The mask assembly according toclaim 15, wherein the two headgear attachment locations are disposedadjacent to and on opposed lateral sides of the opening.
 22. The maskassembly according to claim 15, wherein the first frame and the cushiontogether form the breathing chamber.
 23. The mask assembly according toclaim 15, wherein the opening is between the two second frame openings,the first frame and the second frame are adapted to be interlocked whilean inlet elbow is engaged with the mask assembly, the inlet elbow isconfigured to communicate the supply of breathing gas through theopening, the two headgear attachment locations are adapted to engagewith clips attached to straps of a headgear assembly, the two headgearattachment locations are disposed adjacent to and on opposed lateralsides of the opening, and the first frame and the cushion together formthe breathing chamber.
 24. The mask assembly according to claim 15,wherein the opening is between the two second frame openings, the firstframe and the second frame are adapted to be interlocked while an inletelbow is engaged with the mask assembly, the inlet elbow is configuredto communicate the supply of breathing gas through the opening, the twoheadgear attachment locations are adapted to engage with clips attachedto straps of a headgear assembly, the two headgear attachment locationsare disposed adjacent to and on opposed lateral sides of the opening,and the first frame and the cushion together form the breathing chamber.25. The mask assembly according to claim 15, wherein the substantiallycylindrical surface and the annular opening are closely adjacent to eachother.
 26. A mask assembly for treatment of sleep disorder breathing bydelivering a flow of pressurized gas to a patient, the mask assemblycomprising: a first frame that at least partially delimits a breathingchamber, the first frame including a first substantially cylindricalsurface surrounding an opening to the breathing chamber and defining acentral axis, the opening being configured to allow the flow ofpressurized gas to the breathing chamber; a second frame including asecond substantially cylindrical surface defined at least in part by awall that extends substantially parallel to the central axis with athickness of the wall being normal to the central axis, a memberextending toward a forehead support and two headgear attachmentlocations, the second substantially cylindrical surface at leastpartially overlapping with and passing completely around the firstsubstantially cylindrical surface, and the second frame being configuredto removably interlock with the first frame proximate the opening whenthe first frame and the second frame are moved towards one another alongthe central axis; and a cushion molded to the first frame and includinga side wall and a membrane that includes a sealing surface adapted toseal around at least a patient's nose, the membrane being connected tothe side wall at an outer periphery of the membrane and beingunconnected at an inner periphery of the membrane; wherein the sealingsurface is on an opposite side of the first frame with respect to theopening, and the first frame comprises a first material and the sealingsurface comprises a second material that is more flexible than the firstmaterial and the first substantially cylindrical surface and a wall ofthe breathing chamber comprise the first material, the second frameincludes two second frame openings discrete from the secondsubstantially cylindrical surface, separated from the secondsubstantially cylindrical surface by at least a thickness of the walland through which the first frame is visible when the first frame andthe second frame are attached to one another, the first frame and thesecond frame have mutual contact points to prevent relative rotation ofthe first frame with respect to the second frame about the opening. 27.The mask assembly according to claim 26, wherein the opening is betweenthe two second frame openings, the first frame and the second frame arerigid and the cushion is flexible, the first frame and the second frameare adapted to be interlocked while an inlet elbow is engaged with themask assembly and the inlet elbow is configured to communicate the flowof pressurized gas through the opening, and the two headgear attachmentlocations are adapted to engage with clips attached to straps of aheadgear assembly and are disposed adjacent to and on opposed lateralsides of the opening, the first frame and the cushion together form thebreathing chamber.
 28. The mask assembly according to claim 26, whereinthe wall extends substantially parallel to the central axis a distancethat is greater than a thickness of an adjacent wall of the secondframe.
 29. The mask assembly according to claim 26, wherein the firstsubstantially cylindrical surface and the second substantiallycylindrical surface are closely adjacent to each other.